WO2000030973A1 - Process for making ammonia from heterogeneous feedstock - Google Patents
Process for making ammonia from heterogeneous feedstock Download PDFInfo
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- WO2000030973A1 WO2000030973A1 PCT/US1999/027639 US9927639W WO0030973A1 WO 2000030973 A1 WO2000030973 A1 WO 2000030973A1 US 9927639 W US9927639 W US 9927639W WO 0030973 A1 WO0030973 A1 WO 0030973A1
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- ammonia
- hydrogen
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- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 title claims abstract description 156
- 229910021529 ammonia Inorganic materials 0.000 title claims abstract description 76
- 238000000034 method Methods 0.000 title claims description 39
- 230000008569 process Effects 0.000 title claims description 37
- 239000007789 gas Substances 0.000 claims abstract description 130
- 238000003786 synthesis reaction Methods 0.000 claims abstract description 66
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 65
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 20
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 18
- 238000002156 mixing Methods 0.000 claims abstract description 6
- 239000000446 fuel Substances 0.000 claims abstract description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims description 54
- 229910002092 carbon dioxide Inorganic materials 0.000 claims description 39
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 24
- 239000001257 hydrogen Substances 0.000 claims description 24
- 229910052739 hydrogen Inorganic materials 0.000 claims description 24
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 23
- 238000010926 purge Methods 0.000 claims description 21
- 239000000203 mixture Substances 0.000 claims description 16
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 15
- 239000001569 carbon dioxide Substances 0.000 claims description 15
- 238000006243 chemical reaction Methods 0.000 claims description 13
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 12
- 229910052757 nitrogen Inorganic materials 0.000 claims description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 11
- 229910052760 oxygen Inorganic materials 0.000 claims description 10
- 238000011084 recovery Methods 0.000 claims description 10
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 9
- 239000003054 catalyst Substances 0.000 claims description 9
- 239000001301 oxygen Substances 0.000 claims description 9
- 229910002091 carbon monoxide Inorganic materials 0.000 claims description 7
- 239000011261 inert gas Substances 0.000 claims description 7
- 238000004519 manufacturing process Methods 0.000 claims description 7
- 229910052786 argon Inorganic materials 0.000 claims description 6
- 238000004064 recycling Methods 0.000 claims description 3
- 239000002826 coolant Substances 0.000 claims 1
- 239000000498 cooling water Substances 0.000 claims 1
- 238000001179 sorption measurement Methods 0.000 abstract description 21
- 230000001590 oxidative effect Effects 0.000 abstract 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 13
- 229910002090 carbon oxide Inorganic materials 0.000 description 10
- 238000007254 oxidation reaction Methods 0.000 description 8
- 230000003647 oxidation Effects 0.000 description 7
- 238000000926 separation method Methods 0.000 description 6
- 239000003463 adsorbent Substances 0.000 description 5
- 239000006096 absorbing agent Substances 0.000 description 4
- 238000001816 cooling Methods 0.000 description 4
- 239000012535 impurity Substances 0.000 description 4
- 238000000629 steam reforming Methods 0.000 description 4
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 235000011114 ammonium hydroxide Nutrition 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 238000009833 condensation Methods 0.000 description 3
- 230000005494 condensation Effects 0.000 description 3
- 230000001276 controlling effect Effects 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- 239000002699 waste material Substances 0.000 description 3
- 239000004215 Carbon black (E152) Substances 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 230000003197 catalytic effect Effects 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 229910010272 inorganic material Inorganic materials 0.000 description 2
- 239000011147 inorganic material Substances 0.000 description 2
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Chemical compound [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 238000001193 catalytic steam reforming Methods 0.000 description 1
- 238000012993 chemical processing Methods 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 239000000295 fuel oil Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 150000002334 glycols Chemical class 0.000 description 1
- XLYOFNOQVPJJNP-ZSJDYOACSA-N heavy water Substances [2H]O[2H] XLYOFNOQVPJJNP-ZSJDYOACSA-N 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- VUZPPFZMUPKLLV-UHFFFAOYSA-N methane;hydrate Chemical compound C.O VUZPPFZMUPKLLV-UHFFFAOYSA-N 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 229910000069 nitrogen hydride Inorganic materials 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 229910000027 potassium carbonate Inorganic materials 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000002407 reforming Methods 0.000 description 1
- 238000005057 refrigeration Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 238000005201 scrubbing Methods 0.000 description 1
- 230000001932 seasonal effect Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000011885 synergistic combination Substances 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
- C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
- C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
- C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
- C01B3/48—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents followed by reaction of water vapour with carbon monoxide
-
- C—CHEMISTRY; METALLURGY
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- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
- C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
- C01B3/025—Preparation or purification of gas mixtures for ammonia synthesis
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
- C01B3/50—Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification
- C01B3/506—Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification at low temperatures
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
- C01B3/50—Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification
- C01B3/56—Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification by contacting with solids; Regeneration of used solids
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01C—AMMONIA; CYANOGEN; COMPOUNDS THEREOF
- C01C1/00—Ammonia; Compounds thereof
- C01C1/02—Preparation, purification or separation of ammonia
- C01C1/04—Preparation of ammonia by synthesis in the gas phase
- C01C1/0405—Preparation of ammonia by synthesis in the gas phase from N2 and H2 in presence of a catalyst
- C01C1/0458—Separation of NH3
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01C—AMMONIA; CYANOGEN; COMPOUNDS THEREOF
- C01C1/00—Ammonia; Compounds thereof
- C01C1/02—Preparation, purification or separation of ammonia
- C01C1/04—Preparation of ammonia by synthesis in the gas phase
- C01C1/0405—Preparation of ammonia by synthesis in the gas phase from N2 and H2 in presence of a catalyst
- C01C1/0476—Purge gas treatment, e.g. for removal of inert gases or recovery of H2
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- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/02—Processes for making hydrogen or synthesis gas
- C01B2203/025—Processes for making hydrogen or synthesis gas containing a partial oxidation step
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- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/02—Processes for making hydrogen or synthesis gas
- C01B2203/0283—Processes for making hydrogen or synthesis gas containing a CO-shift step, i.e. a water gas shift step
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
- C01B2203/042—Purification by adsorption on solids
- C01B2203/0425—In-situ adsorption process during hydrogen production
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
- C01B2203/042—Purification by adsorption on solids
- C01B2203/043—Regenerative adsorption process in two or more beds, one for adsorption, the other for regeneration
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
- C01B2203/046—Purification by cryogenic separation
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- C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
- C01B2203/0465—Composition of the impurity
- C01B2203/0475—Composition of the impurity the impurity being carbon dioxide
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/06—Integration with other chemical processes
- C01B2203/068—Ammonia synthesis
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- C01B2203/08—Methods of heating or cooling
- C01B2203/0872—Methods of cooling
- C01B2203/0888—Methods of cooling by evaporation of a fluid
- C01B2203/0894—Generation of steam
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- C01B2203/10—Catalysts for performing the hydrogen forming reactions
- C01B2203/1041—Composition of the catalyst
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- C01B2203/10—Catalysts for performing the hydrogen forming reactions
- C01B2203/1041—Composition of the catalyst
- C01B2203/1076—Copper or zinc-based catalysts
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/12—Feeding the process for making hydrogen or synthesis gas
- C01B2203/1205—Composition of the feed
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/14—Details of the flowsheet
- C01B2203/146—At least two purification steps in series
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/14—Details of the flowsheet
- C01B2203/146—At least two purification steps in series
- C01B2203/147—Three or more purification steps in series
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/14—Details of the flowsheet
- C01B2203/148—Details of the flowsheet involving a recycle stream to the feed of the process for making hydrogen or synthesis gas
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/50—Improvements relating to the production of bulk chemicals
- Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts
Definitions
- This invention relates to processes for making ammonia. More specifically, this invention relates to processes for manufacturing ammonia on an industrial scale from a heterogeneous feedstock containing a time varying variety of different materials having different carbon contents and including, for example, solid or liquid carbon-containing waste materials.
- Ammonia is produced on an industrial scale by the catalytic conversion of nitrogen and hydrogen at high pressures and temperatures. While the nitrogen typically comes from air, the hydrogen is usually produced by reacting carbon-containing feedstocks with steam (steam reforming) or oxygen (partial oxidation). For example, methane or natural gas can be catalytically steam reformed (CH 4 + H 2 O ->CO + 3H 2 ). In contrast, coal, coke and naphtha or heavy oils, for example, can undergo reactions including partial oxidation (2C+ O 2 - 2CO) and water gas reaction (C + H 2 O - CO + H,).
- the steam reforming and partial oxidation reactions form a gas ("synthesis gas"), which usually contains primarily CO 2 and H 2 along with a small amount of CO 2 .
- the CO in the synthesis gas is combined with steam in the so- called “shift reaction” to form a shifted gas containing CO-,, and H 2 (CO + H 2 O - H 2 ).
- shift reaction After separating the carbon oxides and other undesired components in the shift gas from the H 2 , H 2 is combined with N 2 to form ammonia.
- the bulk of the CO 2 can be removed by absorption (i.e., scrubbing), using suitable physical solvents, such as methanol and esters of oligoethylene glycols, or chemical-type solvents, such as hot potassium carbonate and solutions of amines.
- suitable physical solvents such as methanol and esters of oligoethylene glycols
- chemical-type solvents such as hot potassium carbonate and solutions of amines.
- the conventional methanation step is essentially the reverse of the steam reforming step, but carried out at lower temperature, wherein CO and CO 2 are caused to react with hydrogen to form methane and water (CO + 3H 2 ⁇ > CH 4 + H,O; CO 2 + 4H 2 -» CH 4 + 2H 2 O).
- carbon oxides in the shifted gas can be separated from the H 2 , used for ammonia synthesis through the use of pressure swing adsorption ("PSA") techniques.
- PSA pressure swing adsorption
- a PSA system is capable of selectively adsorbing CO 2 , CO, CH 4 , and other impurities from H 2 and from a portion of any N 2 , present in the shifted gas mixture leaving the shift reactor.
- the product gas is not discharged continuously, and therefore, a plurality of adsorbent beds are provided in parallel with one another to achieve a measure of continuity in the product output flow.
- a selectable component of the feed gas mixture is adsorbed so that the gas discharged at the other end of the adsorption bed is the component-depleted product gas.
- Such adsorption occurs at the highest pressure of the process, which is generally the input feed pressure.
- This high pressure portion of the separation process cycle is followed by a depressurization portion of the cycle wherein the gas within the adsorption bed is reversed in its direction of flow and released at the inlet end of the adsorption bed.
- the gas which is thus exhausted is rich with the desorbate, which corresponds to the component of the feed gas which has been adsorbed and is released upon reduction in the pressure.
- the depressurized exhaust portion of the cycle is followed by introduction of a purge gas at the product outlet end of the adsorption.
- a new cycle is commenced with the introduction once again of pressurized feed gas after purging has been completed.
- the H 2 in the shifted gas is reacted with N 2 that has accompanied the H 2 through the shift reactor. This is accomplished by compressing the H 2 and N 2 , and feeding these gases into an ammonia synthesis unit where the H 2 and N 2 are converted into ammonia (3H 2 + N 2 - 2NH 3 ).
- the yield of this ammonia synthesis reaction is typically considerably less than 100%, NH 3 in the product stream exiting the ammonia synthesis unit is collected from the product stream by cooling and condensation, and at least a portion of the unreacted H 2 and N 2 in the product stream is recycled through the ammonia synthesis unit.
- U.S. Patent No. 4,572,829 discloses a process in which a reformed gas mixture to be employed for ammonia synthesis is purified, following shift conversion, by the selective catalytic oxidation of residual carbon monoxide and the selective adsorption of carbon dioxide and water so as to render unnecessary the methanation of carbon oxides.
- U.S. Patent No. 4,592,860 discloses a process and apparatus for ammonia synthesis gas production using a PSA system.
- U.S. Patent No. 4,725,380 discloses the production of ammonia synthesis gas by partial oxidation of a hydrocarbon feed stock, using air, oxygen enriched air, or oxygen depleted air, in admixture with steam, followed by shift and the removal of the excess of nitrogen, and also impurities such as carbon oxides and methane, by pressure swing adsorption.
- U.S. Patent No. 5,252,609 discloses synthesis gas production comprising primary catalytic steam reforming a first stream of desulfurized hydrocarbon feed stock, optionally followed by secondary reforming using an oxygen-containing gas, and then cooling; adiabatically low temperature steam reforming a second stream of the feed stock, preferably adding a hydrogen-containing gas, and then subjecting the product to partial oxidation with an oxygen-containing gas, and then cooling; and mixing the cooled products.
- U.S. Patent No. 5,254,368 discloses a periodic chemical processing system with a single bed rapid cycle PSA device.
- heterogeneous feedstock refers to a non-homogeneous carbon-containing feedstock, containing a mixture of dissimilar feedstock components, in which the composition of the feedstock can vary widely over time as the result of variations in the composition of one or more of the feedstock components and/or variations in the relative amounts of the components in the feedstock.
- This invention provides a process for making ammonia from a heterogeneous feedstock.
- the process partially oxidizes, at low pressure, the heterogeneous feedstock to form a synthesis gas containing CO among other components such as CO 2 and H 2 ; compresses this gas; isothermally shifts the CO and steam to form a shifted gas containing CO 2 and H 2 ; preferably removes at least a portion of the CO 2 and most preferably less than 80% and greater than 60% of the CO 2 and then passes the shifted gas through a pressure swing absorber to separate a high purity H 2 stream from a tail stream containing residual carbon oxides and H 2 ; and reacts a mixture of the high purity N 2 stream and a high purity stream to form an ammonia product stream.
- the removal of the CO 2 upstream of the pressure swing absorber may be accomplished using a suitable process such as, for example, the cryogenic process disclosed by Reddy in the US Patent Application (60/070781 dated January 8, 1998), incorporated herein by reference, or a solvent based system. It was discovered that by utilizing the process as disclosed by Reddy upstream of the pressure swing adsorption unit, a number of advantages may be realized as described in tile following:
- the Ar removal may range from 10 to as much as 40 percent and thus, the recovered H 2 stream from the pressure swing adsorption unit will be depleted of Ar, reducing a build-up of Ar within the ammonia synthesis unit.
- the reduced inserts concentration within the ammonia synthesis loop reduces the purge gas rate and reduces the optimum operating pressure of the synthesis unit, resulting in higher ammonia production and reduced operating and capital costs, especially of compression.
- a portion of the recovered may be utilized for inerting purposes, the Ar accompanying it will not effect unfavorably tile characteristics of the CO 2 stream since Ar has a molecular weight very close to that of CO 2 .
- the ammonia synthesis unit From the ammonia synthesis unit, two streams are purged, one stream containing much higher concentration of ammonia than the other stream.
- the relatively small volume of the ammonia rich low pressure gas stream from the ammonia synthesis loop makes it feasible to recover ammonia product from the flash gas by cryogenic condensation, thus increasing the recovery of anhydrous ammonia above what is possible conventionally.
- the stream after cryogenic separation may be combined with the second reduced purge stream and the remaining portions may be recovered by aqua wash.
- Fig. 1 is a schematic of an embodiment of the present invention.
- Fig. 1 is a process schematic detailing embodiments of the present invention.
- a carbon-containing heterogeneous feedstock stream A is fed along with an oxygen stream B to gasifier in the gasifier/gas cleanup unit 1.
- Solid and liquid carbon-containing waste materials containing large amounts of inorganic material are processible as heterogeneous feedstock A according to the present invention, as long as the net heating value of the heterogeneous feedstock A is greater than about 3,000 Btu/lb.
- Examples of the carbon-containing waste material that can be processed according to the present invention include oil-contaminated dirt, demolition debris, respirator masks, paint and contaminated rags.
- gasifier/gas cleanup unit 1 carbon in heterogeneous feedstock A is partially oxidized to form a synthesis gas D containing primarily CO.
- the inorganic residue E is removed from the gasifier/gas cleanup unit 1.
- the inorganic residue E contains the inorganic material present in the heterogeneous feedstock A.
- the inorganic residue E can include, for example, steel, glass and concrete.
- the present invention is not limited by the composition of the inorganic residue E.
- the gasifier/gas cleanup unit I is operated at low pressure so that feedstock solids of a large size, i.e., drums, supersacks, etc., can be fed to the gasifier unit 1.
- an open pathway is maintained from the heterogeneous feed stock A in the gasifier/gas cleanup unit I to the atmosphere outside of the gasifier unit 1 so that the pressure inside the gasifier unit I remains at approximately atmospheric pressure (0 psig).
- the pressure in gasifier/gas cleanup unit I can range between, for example, about 0 psig and about 50 psig.
- the temperature in the gasifier can range between, for example, about 2000° F and about 3000° F.
- the carbon content in the heterogeneous feedstock A is varied by more than about 30 weight % points of the heterogeneous feedstock over a 24-hour period.
- the heterogeneous feedstock A can comprise less than about 50 weight % of carbon as free carbon or in combination with other elements. However, at least about 10 weight % of the heterogeneous feed stock must be in the form of carbon for the present invention to be operable.
- the composition and quantity of the synthesis gas D produced by the gasifier/gas cleanup unit 1 can vary considerably.
- Synthesis gas D containing CO, H2 and CO 2 , is drawn from gasifier/gas cleanup unit 1 and fed to synthesis gas compressor 2. Although the synthesis gas D contains primarily CO and H 2 , lesser amounts of CO 2 , N 2 and other gases, such as Ar, may also be present.
- Synthesis gas compressor 2 compresses the synthesis gas D to a pressure of 350 psig or more to form a compressed synthesis gas F. In embodiments, synthesis gas compressor 2 can compress the synthesis gas to a pressure of approximately 500 psig.
- Pressurized steam G is then mixed with the compressed synthesis gas F to form a wet compressed synthesis gas J.
- Steam G is added as necessary to adjust the temperature of wet compressed synthesis gas J to the correct water/dry gas ratio and the correct temperature for the shift catalyst, as in all conventional ammonia processes.
- the water/dry gas ratio preferably ranges between, for example, about 2 and about 4
- the temperature of the shift catalyst preferably ranges between about 400 °F and about 500 °F.
- Steam G can be at a temperature of between about 600 °F and about 750 °F, and at a pressure between about 350 psig and about 600 psig.
- the wet compressed synthesis gas J is then fed to shift reactor unit 3.
- shift reactor unit 3 the CO and H 2 O in the wet compressed synthesis gas J undergoes the shift reaction (CO + H 2 O ⁇ CO 2 + H 2 ) to form a shifted gas K containing CO 2 and H ⁇ .
- the shift reaction in shift reactor unit 3 is carried out isothermally, rather than adiabatically, because the CO concentration in wet compressed synthesis gas J fluctuates too much to accomplish temperature moderation by controlling the inlet temperature to the shift reactor or the steam to gas ratio, as in conventional adiabatic processes or by recycling gases.
- Shift reactor unit 3 can be maintained under essentially isothermal conditions by cooling the catalyst bed in shift reaction unit 3 with water passing through tubes immersed in the bed and under such pressure that the water boils, raising steam.
- Shifted gas K is then cooled and fed to a cryogenic unit 8 for CO 2 recovery (stream U).
- the gases KK rich in H 2 leaving the CO 2 recovery unit are then fed to the pressure swing adsorption unit 4.
- Pressure swing adsorption unit 4 separates the components of H 2 rich gas KK into a high purity H 2 stream L without any carbon oxides (or a mixture of H, and N 2 without any carbon oxides when N 2 is used as the sweep gas in the pressure swing adsorption unit to regenerate the adsorbents), and a first tail stream M comprising CO 2 less than about 20% H 2 (and N 2 when N 2 is used as the sweep gas in the pressure swing adsorption unit to regenerate the adsorbents in this unit).
- high purity H 2 stream L comprises at least 99% H 2 when N 2 is not used as the sweep gas, or a mixture of H 2 and N 2 when N 2 is used as the sweep gas.
- the pressure swing adsorption unit 4 maintains the H2 concentration in the high purity H 2 stream L above about 99%, preferably above about 99.9% expressed on a N 2 free basis, regardless of system upset or turndown, that is, when the feed rate to the gasifier or to the pressure swing adsorption unit is reduced.
- the gas stream L which is a mixture of H 2 and N 2 when N 2 is used as sweep gas or high purity H 2 stream when N 2 is not used as the sweep gas is mixed with a high purity N 2 stream P, containing at least 99% N 2 , preferably at least 99.99% N 2 , to form a mixed stream having a molar ratio of about 3 moles of H 2 to about 1 mole of N 2 .
- the high purity N 2 stream is provided by the air separation unit that also provides high purity O 2 for the gasifier.
- the mixed stream Q is then compressed in compressor 5 to a pressure of between about 1500 psig and 3000 psig to form a compressed mixed stream R.
- Compressed mixed stream R is then fed to ammonia synthesis unit 6, where at least part of the H 2 and the N 2 in the compressed mixed stream R is converted into ammonia.
- the pressure in ammonia synthesis unit 6 ranges between, for example, about 1500 psig and about 3000 psig.
- adsorbents and catalysts employed in gasifier/gas cleanup unit 1 , shift reactor unit 3 and ammonia synthesis unit 6 are well known to the skilled artisan.
- Examples of conventional adsorbents/catalysts include, for example: activated carbon in the gasifier/gas cleanup unit 1; copper based catalyst for the shift reactor unit 3; and iron based catalyst for the ammonia synthesis unit 6.
- Tail stream M may be recycled by mixing with synthesis gas D whenever the production of synthesis gas D in gasifier unit 1 is less than a maximum that can be produced by gasifier unit I or in order to maintain a constant pressure and flowrate at the inlet of the syn gas compressor.
- Product stream S from ammonia synthesis unit 6 is fed to refrigerated (chiller) condenser and separation system 7, which separates gas stream TT from first ammonia product stream T using conventional refrigeration techniques.
- the pressure of product stream S can range between, for example, about 1500 psig and about 3000 psig, and a temperature in chiller condenser 7 can range between, for example, about -55°F and about 45°F.
- the gas stream TT is divided into (1) a first purge stream SS which may be optionally fed to cryogenic condenser 10, where second ammonia product stream Z may be separated and producing a second purge stream YY or directly purged from the system as stream SS, and (2) a recycle gas stream AA which is mixed with compressed mixed stream R before being recycled into ammonia synthesis unit 6.
- the high pressure ammonia stream first separated in the chiller condenser/separation unit is reduced in pressure while producing a second purge stream Y which is fed to the cryogenic condenser 10 producing the second ammonia product stream Z.
- Gas leaving the cryogenic condenser 10 constitutes the third purge stream YY.
- the purge stream YY may be treated in an aqua wash system (not shown in Fig. 1) to recover the remaining ammonia contained in the stream while producing aqua ammonia product. Since the demand for the aqua ammonia product is seasonal, the configuration disclosed herein provides flexibility for controlling the amount of the anhydrous ammonia product and the aqua ammonia product produced by the plant by controlling the amount of purge gas or gasses entering the cryogenic condenser 10. Because of the reduced volume of second ammonia-containing purge stream Y, in comparison with conventional processes, it is economically possible to recover from the ammonia synthesis loop the ammonia product Z contained in purge stream Y by cryogenic condensation.
- the present invention does not include a step of removing CO 2 from the shifted gas K or the first tail stream M by using a CO 2 absorber/scrubber.
- the present invention does not include a methanation step of converting O 2 , CO and CO in the feed gas stream L to the ammonia unit which forms CH 4 and H 2 O because of the very high purity of stream L (on a N 2 free basis) produced by the pressure swing it enters ammonia synthesis unit 6, this embodiment, relative to conventional processes, (1) reduces the ammonia synthesis pressure required for the same conversion efficiency per pass through ammonia synthesis unit 6 by about one fourth (i.e., 2450 psig to 1750 psig), (2) reduces the purge fraction necessary to minimize the argon build up within the synthesis unit 6, and (3) increases the ammonia recovery by reducing the losses in first purge stream SS and second purge stream Y.
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- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Combustion & Propulsion (AREA)
- Analytical Chemistry (AREA)
- Health & Medical Sciences (AREA)
- General Health & Medical Sciences (AREA)
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Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
MXPA01005335A MXPA01005335A (en) | 1998-11-25 | 1999-11-22 | Process for making ammonia from heterogeneous feedstock. |
CA002352576A CA2352576A1 (en) | 1998-11-25 | 1999-11-22 | Process for making ammonia from heterogeneous feedstock |
AU18264/00A AU1826400A (en) | 1998-11-25 | 1999-11-22 | Process for making ammonia from heterogeneous feedstock |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/200,150 US6086840A (en) | 1998-11-25 | 1998-11-25 | Process for making ammonia from heterogeneous feedstock |
US09/200,150 | 1998-11-25 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2000030973A1 true WO2000030973A1 (en) | 2000-06-02 |
Family
ID=22740542
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1999/027639 WO2000030973A1 (en) | 1998-11-25 | 1999-11-22 | Process for making ammonia from heterogeneous feedstock |
Country Status (5)
Country | Link |
---|---|
US (1) | US6086840A (en) |
AU (1) | AU1826400A (en) |
CA (1) | CA2352576A1 (en) |
MX (1) | MXPA01005335A (en) |
WO (1) | WO2000030973A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1401766A1 (en) * | 2001-06-28 | 2004-03-31 | Fluor Corporation | Improved ammonia plant configurations and methods |
WO2006097703A1 (en) * | 2005-03-14 | 2006-09-21 | Geoffrey Gerald Weedon | A process for the production of hydrogen with co-production and capture of carbon dioxide |
FR2961802A1 (en) * | 2010-06-29 | 2011-12-30 | Air Liquide | Combined production of hydrogen and carbon dioxide from hydrocarbon mixture comprises e.g. reforming hydrocarbon mixture to give synthesis gas, cooling the gas, oxidation reaction, cooling and drying the gas and separating the gas |
Families Citing this family (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2003051491A1 (en) * | 2001-12-18 | 2003-06-26 | Fluor Corporation | Psa sharing |
ATE353701T1 (en) | 2002-03-16 | 2007-03-15 | Haldor Topsoe As | RECOVERY OF AMMONIA FROM A DRAIN GAS STREAM |
EP1607371A1 (en) * | 2004-06-18 | 2005-12-21 | Ammonia Casale S.A. | Process for producing ammonia on the basis of nitrogen and hydrogen obtained from natural gas |
US7695708B2 (en) * | 2007-03-26 | 2010-04-13 | Air Products And Chemicals, Inc. | Catalytic steam reforming with recycle |
DE102007015245A1 (en) * | 2007-03-29 | 2008-10-02 | Linde Ag | Process and apparatus for producing synthesis gas |
EP2944606A1 (en) * | 2014-05-15 | 2015-11-18 | L'Air Liquide Société Anonyme pour l'Etude et l'Exploitation des Procédés Georges Claude | Process for generating hydrogen from a fischer-tropsch off-gas |
EP3299336A1 (en) * | 2016-09-23 | 2018-03-28 | Casale SA | A process for nitric acid production |
FR3088925B1 (en) * | 2018-11-27 | 2021-06-11 | Air Liquide | Process for producing hydrogen by steam reforming and CO conversion |
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US4409196A (en) * | 1979-04-24 | 1983-10-11 | Foster Wheeler Energy Corporation | Synthesis gas for ammonia production |
US4524056A (en) * | 1983-07-05 | 1985-06-18 | Foster Wheeler Energy Corporation | Process for the production of ammonia |
US4695442A (en) * | 1984-02-03 | 1987-09-22 | Imperial Chemical Industries Plc | Ammonia synthesis process |
US4780298A (en) * | 1986-02-26 | 1988-10-25 | Foster Wheeler Usa Corporation | Ammonia synthesis |
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US4414191A (en) * | 1981-08-07 | 1983-11-08 | Union Carbide Corporation | Process for the production of ammonia |
US4755361A (en) * | 1984-02-07 | 1988-07-05 | Union Carbide Corporation | Apparatus for ammonia synthesis gas production |
US4592860A (en) * | 1984-02-07 | 1986-06-03 | Union Carbide Corporation | Process and apparatus for ammonia synthesis gas production |
US4553981A (en) * | 1984-02-07 | 1985-11-19 | Union Carbide Corporation | Enhanced hydrogen recovery from effluent gas streams |
US4725380A (en) * | 1984-03-02 | 1988-02-16 | Imperial Chemical Industries Plc | Producing ammonia synthesis gas |
US4725381A (en) * | 1984-03-02 | 1988-02-16 | Imperial Chemical Industries Plc | Hydrogen streams |
US4572829A (en) * | 1984-11-09 | 1986-02-25 | Union Carbide Corporation | Ammonia synthesis gas purification |
US5254368A (en) * | 1987-11-02 | 1993-10-19 | University Of Michigan | Periodic chemical processing system |
DE3926575A1 (en) * | 1989-08-11 | 1991-02-14 | Metallgesellschaft Ag | PROCESS FOR CLEANING RAW FUEL GAS FROM THE GASIFICATION OF SOLID FUELS |
EP0522744B1 (en) * | 1991-07-09 | 1997-08-13 | Imperial Chemical Industries Plc | Synthesis gas production |
US5669960A (en) * | 1995-11-02 | 1997-09-23 | Praxair Technology, Inc. | Hydrogen generation process |
-
1998
- 1998-11-25 US US09/200,150 patent/US6086840A/en not_active Expired - Fee Related
-
1999
- 1999-11-22 AU AU18264/00A patent/AU1826400A/en not_active Abandoned
- 1999-11-22 WO PCT/US1999/027639 patent/WO2000030973A1/en active Application Filing
- 1999-11-22 CA CA002352576A patent/CA2352576A1/en not_active Abandoned
- 1999-11-22 MX MXPA01005335A patent/MXPA01005335A/en not_active Application Discontinuation
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
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US4409196A (en) * | 1979-04-24 | 1983-10-11 | Foster Wheeler Energy Corporation | Synthesis gas for ammonia production |
US4524056A (en) * | 1983-07-05 | 1985-06-18 | Foster Wheeler Energy Corporation | Process for the production of ammonia |
US4695442A (en) * | 1984-02-03 | 1987-09-22 | Imperial Chemical Industries Plc | Ammonia synthesis process |
US4780298A (en) * | 1986-02-26 | 1988-10-25 | Foster Wheeler Usa Corporation | Ammonia synthesis |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1401766A1 (en) * | 2001-06-28 | 2004-03-31 | Fluor Corporation | Improved ammonia plant configurations and methods |
EP1401766A4 (en) * | 2001-06-28 | 2011-07-20 | Fluor Corp | Improved ammonia plant configurations and methods |
WO2006097703A1 (en) * | 2005-03-14 | 2006-09-21 | Geoffrey Gerald Weedon | A process for the production of hydrogen with co-production and capture of carbon dioxide |
FR2961802A1 (en) * | 2010-06-29 | 2011-12-30 | Air Liquide | Combined production of hydrogen and carbon dioxide from hydrocarbon mixture comprises e.g. reforming hydrocarbon mixture to give synthesis gas, cooling the gas, oxidation reaction, cooling and drying the gas and separating the gas |
Also Published As
Publication number | Publication date |
---|---|
US6086840A (en) | 2000-07-11 |
MXPA01005335A (en) | 2003-03-27 |
AU1826400A (en) | 2000-06-13 |
CA2352576A1 (en) | 2000-06-02 |
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